Calculate Size of Contactor, Fuse, C.

B, Over Load Relay of

DOL Starter
JUNE 2, 2013 4 COMMENTS

Calculate Size of Contactor, Fuse, C.B, O/L of DOL

Starter

Calculate Size of each Part of DOL starter for The System Voltage 415V ,5HP Three

Phase House hold Application Induction Motor ,Code A, Motor efficiency 80%,Motor RPM
750 ,Power Factor 0.8 , Overload Relay of Starter is Put before Motor.

Basic Calculation of Motor Torque & Current:

Motor Rated Torque (Full Load Torque) =5252xHPxRPM

Motor Rated Torque (Full Load Torque) =5252x5x750=35 lb-ft.

Motor Rated Torque (Full Load Torque) =9500xKWxRPM
Motor Rated Torque (Full Load Torque) =9500x(50.746)x750 =47 Nm

If Motor Capacity is less than 30 KW than Motor Starting Torque is 3xMotor Full Load

Current or 2X Motor Full Load Current.

Motor Starting Torque=3xMotor Full Load Current.

Motor Starting Torque==347=142Nm.
Motor Lock Rotor Current =1000xHPx figure from below Chart/1.732415
Locked Rotor Current
Code

Min

Max

3.14

3.15

3.54

3.55

3.99

4.49

4.5

4.99

2.59

2.6

6.29

6.3

7.09

7.1

7.99

8.99

9.99

10

11.19

11.2

12.49

12.5

13.99

14

15.99

16

17.99

18

19.99

20

22.39

22.4

As per above chart Minimum Locked Rotor Current =1000x5x1/1.732415=7 Amp

Maximum Locked Rotor Current =1000x5x3.14/1.732415=22 Amp.

Motor Full Load Current (Line) =KWx1000/1.732415

Motor Full Load Current (Line) = (50.746)x1000/1.732415=6 Amp.

Motor Full Load Current (Phase)=Motor Full Load Current (Line)/1.732

Motor Full Load Current (Phase)==6/1.732=4Amp

Motor Starting Current =6 to 7xFull Load Current.
Motor Starting Current (Line)=76=45 Amp

(1) Size of Fuse:

Fuse

as per NEC 430-52

Type of

Time Delay

Motor

Fuse

Non-Time Delay Fuse

Single Phase

300%

175%

3 Phase

300%

175%

Synchronous

300%

175%

Wound Rotor

150%

150%

Direct Current

150%

150%

Maximum Size of Time Delay Fuse =300% x Full Load Line Current.
Maximum Size of Time Delay Fuse =300%x6= 19 Amp.
Maximum Size of Non Time Delay Fuse =1.75% x Full Load Line Current.
Maximum Size of Non Time Delay Fuse=1.75%6=11 Amp.

(2) Size of Circuit Breaker:

Circuit Breaker as per NEC 430-52
Type of
Motor

Instantaneous Trip

Inverse Time

Single Phase

800%

250%

3 Phase

800%

250%

Synchronous

800%

250%

Wound Rotor

800%

150%

Direct Current

200%

150%

Maximum Size of Instantaneous Trip Circuit Breaker =800% x Full Load Line

Current.

Maximum Size of Instantaneous Trip Circuit Breaker =800%x6= 52 Amp.

Maximum Size of Inverse Trip Circuit Breaker =250% x Full Load Line Current.

Maximum Size of Inverse Trip Circuit Breaker =250%x6= 16 Amp.

(3) Thermal over Load Relay:

Thermal over Load Relay (Phase):

Min Thermal Over Load Relay setting =70%xFull Load Current(Phase)

Min Thermal Over Load Relay setting =70%x4= 3 Amp

Max Thermal Over Load Relay setting =120%xFull Load Current(Phase)

Max Thermal Over Load Relay setting =120%x4= 4 Amp

Thermal over Load Relay (Phase):

Thermal over Load Relay setting =100%xFull Load Current (Line).

Thermal over Load Relay setting =100%x6= 6 Amp

(4) Size and Type of Contactor:

Contact
Application

or

Making Cap

Non-Inductive or Slightly Inductive ,Resistive Load

AC1

1.5

Slip Ring Motor

AC2

Squirrel Cage Motor

AC3

10

Rapid Start / Stop

AC4

12

Switching of Electrical Discharge Lamp

AC5a

Switching of Electrical Incandescent Lamp

AC5b

1.5

Switching of Transformer

AC6a

12

Switching of Capacitor Bank

AC6b

12

Slightly Inductive Load in Household or same type load

AC7a

1.5

Motor Load in Household Application

AC7b

AC8a

AC8b

AC12

AC13

10

Hermetic refrigerant Compressor Motor with Manual O/L

Reset
Hermetic refrigerant Compressor Motor with Auto O/L
Reset
Control of Restive & Solid State Load with opto coupler
Isolation
Control of Restive Load and Solid State with T/C Isolation

Control of Small Electro Magnetic Load ( <72VA)

AC14

Control of Small Electro Magnetic Load ( >72VA)

AC15

10

As per above Chart

Type of Contactor= AC7b

Size of Main Contactor = 100%X Full Load Current (Line).

Size of Main Contactor =100%x6 = 6 Amp.

Making/Breaking Capacity of Contactor= Value above Chart x Full Load Current

(Line).
Making/Breaking Capacity of Contactor=86= 52 Amp.